HPCL Mumbai Refinery

ContentsContents ContentsContents

• Refinery growthRefinery growth• ProductsProducts• Refinery location & layoutRefinery location & layout• Crude receiving and product dispatching facilitiesCrude receiving and product dispatching facilities• Refinery process unitsRefinery process units• Refinery Block diagrams Refinery Block diagrams • Physical performancePhysical performance• Commitment to EnvironmentCommitment to Environment• Major Projects under implementationMajor Projects under implementation

Refinery GrowthRefinery GrowthRefinery GrowthRefinery Growth

FUELS BLOCK FUELS BLOCK LUBE BLOCKLUBE BLOCK

ErstwhileErstwhile Standard VacuumStandard Vacuum Lube IndiaLube India

CommissionedCommissioned Year 1954Year 1954 Year 1969Year 1969

Capacity expansion Capacity expansion

ORIGINALORIGINAL 1.25 MMTPA1.25 MMTPAIN 1969IN 1969 3.5 ...3.5 ... 165,000 T165,000 TIN 1983IN 1983 225,000 T225,000 TIN 1985IN 1985 5.5 …5.5 …IN 1995IN 1995 335, 000 T *335, 000 T *

* Largest In India* Largest In India

Crudes processed = 43 Crudes processed = 43 Crudes processed = 43 Crudes processed = 43

GippslandHarriet

AnkleshwarMum High

Arab LtArab MixBasrah

Upp ZakumOman

Iran Lt+HyKuwaitDubai

Suez mix

EscravosForcadosQua Iboe

Bonny Light

MiriLabuanTapisLirik

Soviet export Blend

Fuel Products = 13Fuel Products = 13

1.1. PropanePropane

2.2. LPGLPG

3.3. Motor GasolineMotor Gasoline

4.4. Low Aromatic NaphthaLow Aromatic Naphtha

5.5. High Aromatic NaphthaHigh Aromatic Naphtha

6.6. Special Cut NaphthaSpecial Cut Naphtha

7.7. Aviation Turbo FuelAviation Turbo Fuel

8.8. Superior Kerosene OilSuperior Kerosene Oil

9.9. Special cut KeroseneSpecial cut Kerosene

10.10. High Speed Diesel (3 Grades)High Speed Diesel (3 Grades)

11.11. Light Diesel OilLight Diesel Oil

12.12. Fuel Oil ( 2 grades)Fuel Oil ( 2 grades)

13.13. LSHSLSHS

Lube Products = 91. Neutral Oils = 32. Turbine Oils = 23. Industrial Oils = 24. Spindle Oil5. Bright Stock

Specialties = 7Specialties = 71. Hexane2. Solvent 14253. MTO4. CBFS5. RPO6. Bitumen (3 Grades)7. Sulfur

Total Products = 29Total Products = 29Total Products = 29Total Products = 29

Product MixProduct MixProduct MixProduct Mix

LPG

3%Petrol

5%Naphtha

13%

ATF

9%

SKO

6%

HSD

27%

LDO

4%

Lubes

4%

Bitumen

6%

IFO/LSHS

20%

Others

3%

Refinery Location Refinery Location

Refinery Layout Refinery Layout Refinery Layout Refinery Layout

Crude receiving and Product shipment facilitiesCrude receiving and Product shipment facilities

Vashi / Loni / Sewri

/Wadala Mazagaon

RCFRCF

JAWAHER JAWAHER DWEEPDWEEP

PRIPAUPRIPAU

MANIFOLDMANIFOLD

ONGC URANONGC URAN

42”

24”

36”

HP REFINERYHP REFINERY

24”

BH Gas

Nap./IFO/SKO/LSHS/HSD LPG

A T

F

SAHAR / SANTACRUZSAHAR / SANTACRUZ MahulMahulTerminalTerminal

Hex/Sol/M

TO/RPO/

CBFS

MS/HSD/SKO/LDO

IFO / Lubes

BPCLBPCL

LSHS

Naphtha

Bitumen

Refinery Process Units Refinery Process Units Refinery Process Units Refinery Process Units

Fuels BlockFuels Block

Crude Distillation - 2

Vacuum Distillation - 2

Naphtha stabilizers - 2

Fluidized Catalytic Cracking

Diesel Hydro De Sulfurization

Hexane

Propane

Lube BlockLube BlockVacuum DistillationSolvent Extraction - 3Propane De-waxingPropane De-AsphaltingIndustrial Oil Hydrofiner

UtilitiesUtilitiesCaptive Power Plant - 5 GTG’sEffluent Treatment Plants - 2Boiler House Cooling Towers Instrument/utility air system Tankage

Mumbai Refinery Process unitsMumbai Refinery Process unitsMumbai Refinery Process unitsMumbai Refinery Process unitsLPG

LS

HS

Stabilizer

Treating

NaphthaATF

DHDSHSDSKO/MTOSulfur

LDO

FR

CDU

VDUs

SEUs

PDA

IOH

PDU

FRE

CDU

VDU

FCC

Spindle Oil150 N500 N1300 NBright StockIO-100IO-1600

Bitumen

Gasoline

LSHS

HMU

IFO

Hexane Hexane /Solvent/Solvent

Physical PerformancePhysical PerformancePhysical PerformancePhysical Performance

AchievementsAchievementsAchievementsAchievements

• ISO 14001 Certified Environmental Friendly RefineryISO 14001 Certified Environmental Friendly Refinery

• ISRS Safety rating of 8 – A comparative safety level with International ISRS Safety rating of 8 – A comparative safety level with International RefineriesRefineries

• First Refinery to implement complete OM&S Automation First Refinery to implement complete OM&S Automation

• Computerized Maintenance Management System (CMMS) implemented Computerized Maintenance Management System (CMMS) implemented

• Oil Industry Safety Award 2002-2003 for 1Oil Industry Safety Award 2002-2003 for 1stst Best overall Safety Best overall Safety

Performance amongst Refineries.Performance amongst Refineries.

• DG FASLI (Director General Factory Advice & Labour Institute) awards DG FASLI (Director General Factory Advice & Labour Institute) awards

during 2004-04during 2004-04

– Lowest avg. weighted accident frequency rate for 3Lowest avg. weighted accident frequency rate for 3rdrd consecutive year consecutive year

– Largest number of manhours worked without a fatal/non-fatal accidentLargest number of manhours worked without a fatal/non-fatal accident

• Green-Tech Gold Safety award 2002-03 and 2003-04 for outstanding Green-Tech Gold Safety award 2002-03 and 2003-04 for outstanding

achievement in the field of industrial safety and environment achievement in the field of industrial safety and environment

management.management.

• National Safety Council - Maharashtra Chapter Award: Two Safety awards National Safety Council - Maharashtra Chapter Award: Two Safety awards

for 2002 received from NSC-MC for Longest Accident Free Period & for 2002 received from NSC-MC for Longest Accident Free Period &

Lowest Accident Frequency Rate. Lowest Accident Frequency Rate.

Safety Awards Safety Awards Safety Awards Safety Awards

AwardsAwardsAwardsAwards

• Awards for NMP treating Technology:Awards for NMP treating Technology:

• CSIR Technology awardCSIR Technology award

• Golden Peacock awardGolden Peacock award

• Award for successful implementation of CMMSAward for successful implementation of CMMS

• National Petroleum Management Program (NPMP) award for National Petroleum Management Program (NPMP) award for

excellence, under the enterprise category for creativity and excellence, under the enterprise category for creativity and

innovationinnovation

• Green-Tech Gold award for excellence in maintaining environment for 3 Green-Tech Gold award for excellence in maintaining environment for 3

consecutive years 2002, 2003 and 2004consecutive years 2002, 2003 and 2004

Crude ThruputCrude ThruputCrude ThruputCrude Thruput

5.6 5.6

6.1 6.16.2

5

6

7

2000-01 2001-02 2002-03 2003-04 2004-05

ALL FIG. IN MMTALL FIG. IN MMT

Consistently Achieved more than 100% capacity utilisation

Major ProductsMajor ProductsMajor ProductsMajor Products

0

100

200

300

400

500

600

2000-01 2001-02 2002-03 2003-04 2004-05

0

200

400

600

800

1000

1200

1400

1600

1800

LPG Petrol ATF Diesel

ALL FIG. IN Thou MTALL FIG. IN Thou MT

Consistently maximizing high value, high demand products

Commitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment Protection

• Major environmental projects Major environmental projects

– Implemented over past 2 decades : Rs 935 Cr. (208 Million USD)Implemented over past 2 decades : Rs 935 Cr. (208 Million USD)

– Under implementation (GFECP ): Rs 1152 Cr. ( 256 Million USD)Under implementation (GFECP ): Rs 1152 Cr. ( 256 Million USD)

• Refinery meets stipulations set by MPCB & CPCBRefinery meets stipulations set by MPCB & CPCB

• Extensive green cover in the Refinery & residential complex. Extensive green cover in the Refinery & residential complex.

• Initiated Tank sludge treatment process to recovery oil from sludgeInitiated Tank sludge treatment process to recovery oil from sludge

Commitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment Protection

Environment Protection Projects ImplementedEnvironment Protection Projects ImplementedEnvironment Protection Projects ImplementedEnvironment Protection Projects Implemented

ProjectsProjects Cost (Rs C r.)Cost (Rs C r.) Year of Commsng.Year of Commsng.

Reduced Air PollutionReduced Air Pollution• Mumbai Pune PipelineMumbai Pune Pipeline 61.361.3 19851985• Ambient air Monitoring stations Ambient air Monitoring stations 1.41.4 19891989• Cooling TowersCooling Towers 18.018.0 19851985• CO BoilerCO Boiler 7.07.0 19871987• Lube Oil pipelineLube Oil pipeline 13.013.0 19921992• Continuous stack MonitoringContinuous stack Monitoring 2.52.5 19991999• Diesel Hydro DesulfurizationDiesel Hydro Desulfurization 758.7758.7 2000 2000

Reduced effluent dischargeReduced effluent discharge• Cooling TowersCooling Towers 18.018.0 19851985• MINAS plantsMINAS plants 15.015.0 19921992

Eco friendly SolventsEco friendly Solvents• NMP treating in Hexane NMP treating in Hexane 15.415.4 19971997• NMP solvent in SEUs NMP solvent in SEUs 26.0 26.0 19951995

Green Fuels & Emission Control Project Green Fuels & Emission Control Project Green Fuels & Emission Control Project Green Fuels & Emission Control Project

• ObjectivesObjectives

• To meet EURO-III specifications for MS To meet EURO-III specifications for MS

• Augmentation of crude processing capacity to 7.9 MMTPA Augmentation of crude processing capacity to 7.9 MMTPA

• Project Cost:Project Cost: Rs 1152 Crores (256 Mill. USD)Rs 1152 Crores (256 Mill. USD)

• New Units New Units

• Naphtha SplitterNaphtha Splitter

• Naphtha HydrotreaterNaphtha Hydrotreater

• Catalytic Reforming UnitCatalytic Reforming Unit

• Isomerization unit Isomerization unit

• FCC Gasoline Hydrotreater (Prime G+)FCC Gasoline Hydrotreater (Prime G+)

• Flue Gas Desulfurization UnitFlue Gas Desulfurization Unit

• De NOx FacilitiesDe NOx Facilities

Green Fuels & Emission Control ProjectGreen Fuels & Emission Control ProjectGreen Fuels & Emission Control ProjectGreen Fuels & Emission Control Project

Naphtha

SPLITTER

ISOM

Naphtha HydrotreaterNaphtha Hydrotreater& Isomerization& Isomerization

GASOLINE

POOL

HydrotreaterHydrotreater

IsomerateIsomerate

ReformateReformate

SHU

Selective HydrogenationSelective Hydrogenation& Splitter& Splitter

PRIME G+

Light FCC GasolineLight FCC Gasoline

Heavy FCC GasolineHeavy FCC Gasoline

FCCU CrackedNaphtha

H2

H2

H2

CCR

ReformerReformer

NHT Make up HMake up H22

Light NaphthaLight Naphtha

Heavy NaphthaHeavy Naphtha

LPGLPG

Major MilestonesMajor MilestonesMajor MilestonesMajor Milestones

19541954 Refinery commissionedRefinery commissioned

19691969 Lube refinery commissionedLube refinery commissioned

19771977 II Vacuum Distillation Unit AddedII Vacuum Distillation Unit Added

19831983 Lube Refinery ExpandedLube Refinery Expanded

19851985 Fuels Refinery ExpandedFuels Refinery Expanded

19891989 Captive Power Plant CommissionedCaptive Power Plant Commissioned

1993-941993-94 Achieved 6.0 MMTPA for 1Achieved 6.0 MMTPA for 1stst time time

1994-951994-95 LRE-II Commissioned & Solvent Extraction units converted LRE-II Commissioned & Solvent Extraction units converted

to eco friendly NMPto eco friendly NMP

CONTD.CONTD.

1995-961995-96 Commissioned DCS in all process units of refinery Commissioned DCS in all process units of refinery

1996-971996-97 Highest ever crude t’put of 6.5 MMTPAHighest ever crude t’put of 6.5 MMTPA

1998-991998-99 Commissioned new 14000 BSD (0.65 MMTPA) FCCUCommissioned new 14000 BSD (0.65 MMTPA) FCCU

1999-20001999-2000 DHDS project commissionedDHDS project commissioned

2000-012000-01 implemented CMMSimplemented CMMS

2002-032002-03 Supply of Euro-II Petrol & DieselSupply of Euro-II Petrol & Diesel

2004-052004-05 DHDS-II Project commissioned. Production of Euro-III DHDS-II Project commissioned. Production of Euro-III

DieselDiesel

Major MilestonesMajor MilestonesMajor MilestonesMajor Milestones